WO1996039031A1 - Feuil microporeux contenant un adsorbant microbien - Google Patents

Feuil microporeux contenant un adsorbant microbien Download PDF

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Publication number
WO1996039031A1
WO1996039031A1 PCT/US1996/007902 US9607902W WO9639031A1 WO 1996039031 A1 WO1996039031 A1 WO 1996039031A1 US 9607902 W US9607902 W US 9607902W WO 9639031 A1 WO9639031 A1 WO 9639031A1
Authority
WO
WIPO (PCT)
Prior art keywords
film
film according
group
microbial adsorbent
microbial
Prior art date
Application number
PCT/US1996/007902
Other languages
English (en)
Inventor
Carol Ann Blaney
William Francis Cartwright
David Craige Strack
Original Assignee
Kimberly-Clark Worldwide, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kimberly-Clark Worldwide, Inc. filed Critical Kimberly-Clark Worldwide, Inc.
Priority to AU58821/96A priority Critical patent/AU5882196A/en
Publication of WO1996039031A1 publication Critical patent/WO1996039031A1/fr

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Classifications

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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • A—HUMAN NECESSITIES
    • A01—AGRICULTURE; FORESTRY; ANIMAL HUSBANDRY; HUNTING; TRAPPING; FISHING
    • A01N—PRESERVATION OF BODIES OF HUMANS OR ANIMALS OR PLANTS OR PARTS THEREOF; BIOCIDES, e.g. AS DISINFECTANTS, AS PESTICIDES OR AS HERBICIDES; PEST REPELLANTS OR ATTRACTANTS; PLANT GROWTH REGULATORS
    • A01N25/00—Biocides, pest repellants or attractants, or plant growth regulators, characterised by their forms, or by their non-active ingredients or by their methods of application, e.g. seed treatment or sequential application; Substances for reducing the noxious effect of the active ingredients to organisms other than pests
    • A01N25/34—Shaped forms, e.g. sheets, not provided for in any other sub-group of this main group
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A—HUMAN NECESSITIES
    • A41—WEARING APPAREL
    • A41D—OUTERWEAR; PROTECTIVE GARMENTS; ACCESSORIES
    • A41D31/00—Materials specially adapted for outerwear
    • A41D31/04—Materials specially adapted for outerwear characterised by special function or use
    • A41D31/30—Antimicrobial, e.g. antibacterial
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
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    • A61F13/00—Bandages or dressings; Absorbent pads
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    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
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    • A61F13/00—Bandages or dressings; Absorbent pads
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    • A61F13/51—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the outer layers
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    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
    • C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
    • C08J5/18—Manufacture of films or sheets
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    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
    • A61F13/15—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators
    • A61F13/15203—Properties of the article, e.g. stiffness or absorbency
    • A61F2013/15284—Properties of the article, e.g. stiffness or absorbency characterized by quantifiable properties
    • A—HUMAN NECESSITIES
    • A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61F—FILTERS IMPLANTABLE INTO BLOOD VESSELS; PROSTHESES; DEVICES PROVIDING PATENCY TO, OR PREVENTING COLLAPSING OF, TUBULAR STRUCTURES OF THE BODY, e.g. STENTS; ORTHOPAEDIC, NURSING OR CONTRACEPTIVE DEVICES; FOMENTATION; TREATMENT OR PROTECTION OF EYES OR EARS; BANDAGES, DRESSINGS OR ABSORBENT PADS; FIRST-AID KITS
    • A61F13/00—Bandages or dressings; Absorbent pads
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    • A61F13/53—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium
    • A61F2013/530481—Absorbent pads, e.g. sanitary towels, swabs or tampons for external or internal application to the body; Supporting or fastening means therefor; Tampon applicators characterised by the absorbing medium having superabsorbent materials, i.e. highly absorbent polymer gel materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
    • Y10T428/24826—Spot bonds connect components
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/249967—Inorganic matrix in void-containing component
    • Y10T428/24997—Of metal-containing material
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/249978—Voids specified as micro
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/249986—Void-containing component contains also a solid fiber or solid particle

Definitions

  • the field of the present invention encompasses film materials which possess antimicrobial characteristics.
  • Films have been traditionally used to provide barrier properties in single-use items including, but not limited to, articles of clothing in general, protective apparel, healthcare related products including surgical drapes, gowns, and sterile wrap and personal care absorbent products such as diapers, training pants, incontinence garments, sanitary napkins, bandages, and the like.
  • personal care absorbent products such as infant diapers and adult incontinence products
  • films are used as the outer covers with the purpose of preventing body wastes from contaminating the clothing, bedding, and other aspects of the surrounding environment of use.
  • films are used to prevent exchange of microorganisms between the wearer and the patient.
  • Microporous varieties of films have also been used in such products in an attempt to provide articles with more garment-like attributes, such as the ability to reduce the relative humidity underneath the garment, thus maintaining a higher degree of comfort for the wearer.
  • the use of nonwoven webs and/or microporous films in certain protective apparel has not been without difficulties.
  • utilization of such materials has generated concerns about their ability to prevent transfer of microorganisms because the size of microorganisms such as virus and bacteria are typically much smaller than the pores of microporous films.
  • Nonwoven web materials typically, also are characterized by passageways therethrough which, while they may retard the progress of microbes, do not guarantee complete barrier properties with respect to them. For these reasons, neither of these arrangements has proven to be completely satisfactory in view of the fact that they do not form a complete barrier for microbes.
  • microporous film which allows the passage of water vapor while still being an effective barrier material for microbes such as viruses, bacteria, cysts and nematodes.
  • a film which includes a microbial adsorbent and which is capable of providing a microbial barrier while still being able to allow passage of water vapor.
  • the film has first and second surfaces and defines at least one microporous passageway allowing communication, through the film, between the first and second surfaces. Such communication, in some embodiments, allows the passage of water vapor through the film.
  • a portion of the microporous passageway is defined by the microbial adsorbent so that microbes attempting to pass through the film via a passageway must pass in close proximity to the microbial adsorbent. This arrangement allows the microbial adsorbent to interdict the microbe by adsorbing it and prohibiting its passage through the film.
  • the film may be formed from a thermoplastic polymer.
  • the thermoplastic polymer may be selected from the group including polyolefins, polyamides, polyesters and copolymers and blends in any combination of these and/or any other suitable material.
  • the polyolefin may be selected from the group consisting of polypropylenes, polyethylenes, polybutylenes and copolymers and blends thereof.
  • the polyethylene may be linear low density polyethylene.
  • the film may be a solvent cast film formed from any conventional material known to those in the art as being appropriate for the formation of such solvent cast films.
  • the film may be adapted to adsorb viruses, bacteria, cysts or nematodes or any or all of these.
  • the film may be adapted to adsorb specific types of viruses, bacteria, cysts, nematodes etc., depending upon the use to which it is to be assigned.
  • the film may be designed to not only act as a filter for microbes as a result of the presence of the microbial adsorbent but may also be designed to act as a physical (mechanical) barrier to fluids attempting to pass therethrough.
  • the microbial adsorbent utilized may be one which, in the presence of a generally aqueous fluid, increases its volume at least 1.5 times in no more than 120 seconds.
  • the microbial adsorbent may be one which, in the presence of a generally aqueous fluid, increases its volume at least 1.5 times in no more than 60 seconds.
  • the microbial adsorbent may be one which, in the presence of a generally aqueous fluid, increases its volume at least 1.5 times in no more than 15 seconds.
  • the microbial adsorbent may be one which, in the presence of a generally aqueous fluid, increases its volume at least 2 times in no more than 1 second.
  • the adsorbent will, upon being contacted with the generally aqueous fluid, increase in size and swell.
  • the swelling serves to block the microporous passageway with which the microbial adsorbent is in close proximity. Blockage of the passageway creates a physical barrier within the microporous passageway with the consequence that no further liquid can pass.
  • the film may also include a loading of another particulate material which, itself, swells in the presence of a generally aqueous liquid.
  • particulates of the swellable material and the microbial adsorbent may be incorporated into the film in an agglomerated fashion so that each individual particle contains some of the non-swellable microbial adsorbent and some of the swellable material.
  • the swellable material is one which can increase its volume at least 1.5 times in no more than 120 seconds.
  • the swellable material may be one which, in the presence of a generally aqueous fluid, increases its volume at least 1.5 times in no more than 60 seconds. More particularly, the swellable material may be one which, in the presence of a generally aqueous fluid, increases its volume at least 1.5 times in no more than 15 seconds. Even more particularly, the swellable material may be one which, in the presence of a generally aqueous fluid, increases its volume at least 2 times in no more than 1 second.
  • the microbial adsorbent may be any such adsorbent which is compatible with the film material being utilized.
  • the microbial adsorbent may be a derivitized silane such as, for example, 3 - ( trimethoxysily1 ) pr opy 1 d imethy 1 o c t ade cy 1 ammonium chloride.
  • a derivitized silane such as, for example, 3 - ( trimethoxysily1 ) pr opy 1 d imethy 1 o c t ade cy 1 ammonium chloride.
  • This material was formerly available from the Dow Corning under the trade designation Dow Corning 5700. It now is available from Aegis Environmental.
  • the microbial adsorbent is a heavy metal.
  • the heavy metal may be silver.
  • the microbial adsorbent may be a metallic salt.
  • the metallic salt may be a water- insoluble polyvalent metal salt.
  • the water-insoluble polyvalent metal salt may be a salt of a metal selected from the group including Group IB, Group IIA, Group IIB, Group IIIA, Group IVB, Group VIB metals. More particularly, the metal may be selected from the group including iron, aluminum, lead, magnesium, silver, calcium and alloys of one or more of iron, aluminum, lead, magnesium, silver and calcium.
  • the salt may be selected from the group including hydroxides, phosphates, chromates, oxides and peroxides.
  • the salt may be selected from the group including one or more of ferric hydroxides, ferrous hydroxides, aluminum hydroxides, magnesium hydroxide, magnesium oxide, magnesium peroxide, lead chromate and calcium hydroxide.
  • the microbial adsorbent may be selected from the group including colloidal clays.
  • the colloidal clay may be a bentonite such as sodium bentonite and/or calcium bentonite.
  • the colloidal clay may, in some embodiments, be hectorite.
  • the microbial filter film of the present invention may be advantageously formed into a wide variety of items where it is desired to have a material which allows passage of, for example, water vapor but which prohibits the passage of microbes therethrough.
  • the item may be a garment, such as a surgical gown, foot protectors, face masks, head or hair coverings, aprons, jackets, pants, gloves, coveralls and, generally speaking, all clean room attire.
  • a product such as, for example, a sterile wrap material which is used to maintain the sterile field around a doctor's tools until they are utilized in an operation.
  • the film of the present invention may conveniently be formed into a surgical drape for use on a patient during an operation.
  • breathable refers to any material which has a water vapor transmission rate ( VTR) of at least 300 grams per square meter per 24 hours when measured in accordance with ASTM E 96-80.
  • microbial adsorbent refers to any material which has the ability to hold and/or inactivate microbes such as, for example, viruses, bacteria, cysts and/or nematodes on or near its surface.
  • microporous passageway refers to any passageway which, at some point along its length, has a diameter of fifty (50) microns or less.
  • microporous film refers to a film having a plurality of microporous passageways therethrough to make the film breathable.
  • the microporous film will also have a hydrohead of at least 25 centimeters of water when its hydrohead is measured in accordance with Method 5514 - Federal Test Methods Standard No. 191A.
  • the microporous film may have a hydrohead of at least 50 centimeters of water when so measured.
  • aqueous liquid refers to any liquid which has, as a major component, water. All bodily fluids including, without limitation, blood, saliva, menses, mucus, lymph fluid and urine, are expressly included within this definition. Whether a material is "swellable” is determined by first providing 100 mL of water contained in a glass-stoppered cylinder of 100 L capacity. Next a first two (2) gram portion of the material is dropped onto the surface of the water and allowed to completely settle. Then, a second two (2) gram portion of the material being tested is dropped onto the surface. After two (2) hours, the volume occupied by the material at the bottom of the cylinder is observed.
  • nonwoven web refers to a web that has a structure of individual fibers or filaments which are interlaid, but not in an identifiable repeating manner.
  • spunbond fibers refers to fibers which are formed by extruding molten thermoplastic material as filaments from a plurality of fine, usually circular capillaries of a spinnerette with the diameter of the extruded filaments then being rapidly reduced as by, for example, in U.S. Patent No. 4,340,563 to Appel et al., and U.S. Patent No. 3,692,618 to Dorschner et al., U.S. Patent No. ' 3,802,817 to Matsuki et al., U.S. Patent Nos. 3,338,992 and 3,341,394 to Kinney, U.S. Patent Nos.
  • meltblown fibers means fibers formed by extruding a molten thermoplastic material through a plurality of fine, usually circular, die capillaries as molten threads or filaments into a high velocity, usually heated gas (e.g. air) stream which attenuates the filaments of molten thermoplastic material to reduce their diameter. Thereafter, the meltblown fibers are carried by the high velocity gas stream and are deposited on a collecting surface to form a web of randomly disbursed meltblown fibers.
  • heated gas e.g. air
  • Figure 1 is a schematic, highly enlarged cross-sectional view of a breathable, microbial barrier film designed in accordance with the teachings of the present invention.
  • Figure 2 is a schematic, highly enlarged cross-sectional view of an embodiment of a breathable, microbial barrier film designed in accordance with the teachings of the present invention and where the film also forms a physical barrier to the passage of liquids at the site of contact of the film by such a liquid.
  • Figure 2 illustrates the embodiment in the configuration where the physical barrier has been formed.
  • Figure 3 is a schematic, highly enlarged cross-sectional view of another embodiment of a breathable, microbial barrier film designed in accordance with the teachings of the present invention and where the film forms a physical barrier to the passage of liquids at the site of contact of the film by a liquid.
  • Figure 4 is a schematic representation of a process for forming a laminate having the breathable, microbial barrier film of the present invention incorporated therein.
  • Figure 5 is a schematic, highly enlarged cross-sectional view of a laminate of a nonwoven web and the breathable, microbial barrier film of Figure 1.
  • the film 10 will be formed from a sheet 12 of a thermoplastic material.
  • the film 10 is depicted as having only one microporous passageway 14.
  • typical microporous films 10 possess a multitude of such passageways 14 per square inch.
  • the film 10 is configured so that a particle 16 of a material which is a microbial adsorbent is positioned at some point along the length of the passageway between the first surface 18 of the film 10 and the second surface 20 of the film 10.
  • the passageways 14 will be sized in such a manner as to allow the passage of water vapor through the film 10. That is, the film 10 is breathable.
  • a portion of the microporous passageway 14 is defined by the microbial adsorbent 16 so that microbes (not illustrated) attempting to pass through the film 10 via a passageway 14 must pass in close proximity to the microbial adsorbent 16.
  • This arrangement allows the microbial adsorbent 16 to interdict microbes by adsorbing them and prohibiting their passage through the film 10 while still retaining the breathability of the film 10.
  • thermoplastic material 12 may be selected from the group including polyolefins, polyamides, polyesters and copolymers and blends in any combination of these and/or any other suitable material.
  • the polyolefin may be selected from the group consisting of polypropylenes, polyethylenes, polybutylenes and copolymers and blends thereof.
  • the polyethylene may be linear low density polyethylene.
  • the film 10 may be adapted to adsorb a wide variety of pathogens.
  • the film 10 may be tailored to act as a filter for viruses, bacteria, cysts and/or nematodes.
  • the film 10 may be adapted to adsorb specific types of viruses, bacteria, cysts and/or nematodes depending upon the use to which it is to be assigned. Utilization of a pathogen-specific adsorbent readily accomplishes this result.
  • the film 10 may be designed to not only act as a filter (adsorbent) for microbes as a result of the presence of the microbial adsorbent 16, but may also be designed to act as a physical (mechanical) barrier to fluids attempting to pass therethrough.
  • the microbial adsorbent 16 utilized may be a swellable one which, in the presence of a generally aqueous fluid, to increase its volume at least 1.5 times in no more than 120 seconds.
  • the microbial adsorbent 16 may be one which, in the presence of a generally aqueous fluid, increases its volume at least 1.5 times in no more than 60 seconds.
  • the microbial adsorbent 16 may be one which, in the presence of a generally aqueous fluid, increases its volume at least 1.5 times in no more than 15 seconds. Even more particularly, the microbial adsorbent 16 may be one which, in the presence of a generally aqueous fluid, increases its volume at least 2 times in no more than 1 second. In the event such a microbial adsorbent 16 is utilized, the adsorbent 16 will, upon being contacted with the generally aqueous fluid, increase in size and swell. The swelling serves to block the microporous passageway 14 which is in close proximity to the swellable adsorbent 16.
  • FIG. 2 illustrates an embodiment of the present invention where the microbial adsorbent 16 is swellable and has swollen to seal off or dam up the passageway 14.
  • This arrangement results in a "smart" film 10 in that the film 10 reacts to its being contacted by a liquid only in the area where the liquid contact occurs. Therefore, the film 10 remains breathable because of the presence of numerous other icropores 14 which have not been blocked.
  • a specific example of a swellable microbial adsorbent is bentonite and, in particular, sodium bentonite.
  • the film 10 may also include a loading of another particulate material 22 which, itself, swells in the presence of a generally aqueous liquid.
  • particulates of the swellable material 22 and the microbial adsorbent 16 may be incorporated into the film 10 in an agglomerated fashion so that each individual particle contains some of the non-swellable microbial adsorbent 16 and some of the swellable material 22.
  • the swellable material 22 is one which can increase its volume at least 1.5 times in no more than 120 seconds.
  • the swellable material 22 may be one which, in the presence of a generally aqueous fluid, increases its volume at least 1.5 times in no more than 60 seconds. More particularly, the swellable material 22 may be one which, in the presence of a generally aqueous fluid, increases its volume at least 1.5 times in no more than 15 seconds. Even more particularly, the swellable material 22 may be one which, in the presence of a generally aqueous fluid, increases its volume at least 2 times in no more than 1 second.
  • swellable materials 22 which may be utilized in conjunction with a non- swelling microbial adsorbent 16 include, without limitation, kaolins, diatomaceous earth.
  • the diatomaceous earth may be treated, as is known to those in the art, so as to be positively charged.
  • One constraint in this design is that the microbial adsorbent 16 and the swellable material 22 must both be exposed to the passageway 14 for each to perform their respective functions.
  • the microbial adsorbent 16 may be any such adsorbent 16 which is compatible with the film material 12 being utilized.
  • the microbial adsorbent 16 is a heavy metal.
  • the heavy metal may be silver.
  • the microbial adsorbent 16 may be a metallic salt.
  • the metallic salt may be a water- insoluble polyvalent metal salt.
  • the water-insoluble polyvalent metal salt may be a salt of a metal selected from the group including Group IB, Group IIA, Group IIB, Group IIIA, Group IVB, Group VIB metals. More particularly, the metal may be selected from the group including iron, aluminum, lead, magnesium, silver, calcium and alloys of one or more of iron, aluminum, lead, magnesium, silver and calcium.
  • the salt may be selected from the group including hydroxides, phosphates, chromates, oxides and peroxides.
  • the salt may be selected from the group including one or more of ferric hydroxides, ferrous hydroxides, aluminum hydroxides, magnesium hydroxide, magnesium oxide, magnesium peroxide, lead chromate and calcium hydroxide.
  • the microbial adsorbent 16 may be selected from the group including colloidal clays.
  • the colloidal clay may be a bentonite such as sodium bentonite and/or calcium bentonite.
  • the colloidal clay may be a hectorite.
  • the microbial filter film 10 of the present invention may be advantageously formed into a wide variety of items where it is desired to have a material which allows passage of, for example, water vapor but which prohibits the passage of microbes therethrough.
  • the item may be a garment such as a surgical gown, foot protectors, face masks, head or hair coverings, aprons, jackets, pants gloves, coveralls and, generally speaking, all clean room attire.
  • the film 10 may be incorporated into a product such as, for example, a sterile wrap material which is used to maintain the sterile field around a doctor's tools until they are utilized in an operation.
  • the film 10 of the present invention may conveniently be formed or incorporated into a surgical drape for use on a patient during an operation.
  • the film 10 of the present invention may be made by a wide variety of methods known to those of skill in the art.
  • One method of forming the film 10 is described in detail in U.S. patent application serial number 08/254,207 entitled “Stretch- Thinned Film and Nonwoven Laminate” and filed on June 6, 1994 in the names of Ann Louise McCormack, Lance James Garrett, Jr. and Karen Lynn English.
  • This application is hereby specifically incorporated by reference into the present application in its entirety.
  • films can be made to be breathable by adding filler particles such as calcium carbonate to the film during the film-forming process. Once the particle-filled film has been formed by conventional methods, it is then either stretched or crushed to create passageways therethrough. This action results in the creation of a breathable film.
  • This particular method also results in a configuration where at least one of the particles defines a portion of substantially every passageway. Accordingly, this method is well suited for the formation of the films 10 in accordance with the present invention.
  • These films 10 can be readily manufactured by substituting particles of the microbial adsorbent 16 for the filler material. All other process steps remain essentially the same.
  • the microbial adsorbent 16 selected desirably will not chemically interfere with or adversely affect the extruded film 10 and will have the ability to be relatively uniformly dispersed throughout the film 10.
  • the moisture content of the microbial adsorbent 16 should be maintained at 1%, by weight, or less for satisfactory extrusion to occur.
  • the microbial adsorbent 16 particles will have an average particle size in the range of from about 0.1 to about 7 microns.
  • the maximum size particle which may be utilized will be related to the ultimate thickness (thinness) of the film 10.
  • the film 10 will contain at least about 30%, by weight of the film, of the adsorbent 16.
  • FIG. 4 schematically illustrates a process for forming such a laminate by forming a stretch-thinned film 10 and an nonwoven web 24 into a laminate 26.
  • the film 10 is formed using any type of conventional film forming equipment such as cast or blown equipment. Prior to extrusion, the film-forming material is filled with the microbial adsorbent 16 in particulate form.
  • the film 10 After conventional formation of the film 10, it is sent through a film stretching apparatus to stretch and thin the film to an appropriate thickness which is on the order of 0.55 mils or less.
  • the stretch-thinning step also creates the micropores or passageways 14 through the film 10 as is well known to those of skill in the art.
  • One type of apparatus for such stretch-thinning is a Machine Direction Orienter 27 (MDO) Unit, Model No. 7200 from the Marshall and Williams Company of Buffalo, Rhode Island.
  • Figure 4 also illustrates that while the film layer 10 is being formed and thinned, the fibrous nonwoven web 24 is also being formed.
  • Conventional fibrous nonwoven web 24 forming apparatus 28 such as a spunbond machine, may be used to form the web 24.
  • the long, essentially continuous ⁇ punbonded fibers 30 are deposited onto a forming wire 32 as an unbonded matt 34 and the unbonded matt 34 is then sent through a pair of bonding rolls 36a, 36b to bond the fibers 30 together and increase the tear strength of the resultant web 24.
  • One or both of the rolls 36a, 36b are often heated to aid in bonding.
  • one of the rolls 36a is also patterned so as to impart a discrete bond pattern with a prescribed bond surface area to the web 24.
  • the other roll 36b is usually a smooth anvil roll but this roll 36b may also be patterned if so desired.
  • the two layers are brought together and laminated to one another using a pair of laminating rolls or other means 38a, 38b.
  • the laminating rolls 38a, 38b may be heated.
  • at least one of the rolls 38a may be patterned to create a discrete bond pattern with a prescribed bond surface area for the laminate 26. Generally, the maximum bond point surface area for a given area of surface on one side of the laminate 26 will not exceed about 60 percent of the total surface area.
  • the laminate 26 After the laminate 26 has been formed, it is wound into a roll 40 for subsequent processing. Alternatively, the laminate 26 may continue in-line for further conversion into other items or products. It should be noted that this process may be altered in a number of ways without departing from the spirit and scope of the present invention. For example, a different apparatus can be used for stretch-thinning the film 10. Different fil /nonwoven web forming equipment such as meltblown and bonded carded web equipment may be used in place of the spunbond equipment. In addition, other means for bonding and laminating may be used provided the resultant laminate has the required properties described herein. Lastly, the formation processes for making the film and support layers may be done at a remote site and rolls of the two materials may be unwound into the process.
  • the process shown also may be used to create a three layer laminate.
  • a supply 42 of a second fibrous nonwoven web 44 into the laminating rolls 38a, 38b on a side of the film 10 opposite that of the first fibrous nonwoven web 24.
  • the supply of material for the second fibrous nonwoven web 44 is in the form of a preformed roll 42.
  • layer 42 may be formed directly in-line or it may be preformed and then fed into the process from a supply roll. In either event, the second nonwoven web 44 is fed into the laminating rollers 38a, 38b and is laminated to the film 10 in the same fashion as nonwoven web 24.
  • FIG. 5 is a schematic, highly enlarged cross-sectional view of a two-layer laminate of a nonwoven web 24 and a film 10 made in accordance with the present invention. For purposes of clarity and simplicity, only one micropassageway 14 in the film 10 is illustrated. Those of skill in the art will readily recognize that conventional microporous films will contain a plethora of such passageways on a per square inch or per square centimeter basis. For example, from about 100 to 100,000 or more passageways per square centimeter may be present.

Abstract

L'invention concerne un feuil contenant un adsorbant microbien et qui est capable de constituer une barrière antimicrobienne, tout en laissant passer la vapeur d'eau. Ce feuil possède une première et une deuxième surface et définit au moins un passage microporeux créant une communication à travers le feuil entre la première et la deuxième surface. Une partie du passage microporeux, en particulier, est définie par l'adsorbant microbien, de sorte que les microbes qui tentent de passer à travers le feuil par ce passage doivent passer à proximité étroite de l'adsorbant microbien. De ce fait, l'adsorbant microbien adsorbe les microbes et les empêche de passer à travers le feuil.
PCT/US1996/007902 1995-06-06 1996-05-29 Feuil microporeux contenant un adsorbant microbien WO1996039031A1 (fr)

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AU58821/96A AU5882196A (en) 1995-06-06 1996-05-29 Microporous film containing a microbial adsorbent

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US46905295A 1995-06-06 1995-06-06
US08/469,052 1995-06-06

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CA2221136A1 (fr) 1996-12-12

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